Additive manufacturing method for making holes bounded by thin walls in turbine components

Abstract

A method of forming a passage in a turbine component that includes using an additive manufacturing process to form a first support structure on a first surface of the turbine component; and forming a passage through the first support structure and the turbine component.

What is claimed is: 
     
       1. A method of forming a passage in a turbine component comprising:
 using an additive manufacturing process to form a first support structure on a first surface of the turbine component, wherein the additive manufacturing process includes depositing powder on the first surface of the turbine component, and fusing the powder in a pattern corresponding to a layer of the first support structure; 
 forming a passage through the first support structure and the turbine component; and 
 completely removing the first support structure after forming the passage. 
 
     
     
       2. The method of  claim 1 , further comprising repeating in a cycle the steps of depositing and fusing to build up the first support structure in a layer-by-layer fashion. 
     
     
       3. The method of  claim 1 , further comprising removing at least a portion of the first surface of the turbine component. 
     
     
       4. The method of  claim 1  further comprising forming a second support structure on a second surface of the turbine component. 
     
     
       5. The method of  claim 4  further comprising forming the passage through both the first support structure and the second support structure. 
     
     
       6. The method of  claim 5 , further comprising removing at least a portion of the second support structure after forming the passage. 
     
     
       7. The method of  claim 1 , wherein the component comprises a metal alloy. 
     
     
       8. The method of  claim 1 , wherein the powder comprises a metal alloy. 
     
     
       9. a method of forming a passage in a turbine component comprising:
 using an additive manufacturing process to form a first support structure on a first surface of the turbine component; 
 forming a second support structure on a second surface of the turbine component; 
 forming a passage through the first support structure, the turbine component, and the second support structure; and 
 completely removing the first support structure and the second support structure after forming the passage. 
 
     
     
       10. A method of forming a cooling hole in a turbine component comprising:
 using an additive manufacturing process to form a first support structure on a first surface of the turbine component; 
 forming a second support structure on a second surface of the turbine component; 
 forming a cooling hole through the first support structure, the turbine component, and the second support structure; and 
 completely removing the first support structure and the second support structure after forming the cooling hole. 
 
     
     
       11. The method of  claim 10 , wherein the turbine component is a turbine blade. 
     
     
       12. The method of  claim 11 , wherein the cooling hole is formed at a trailing edge of the turbine blade.